WO2003099079A2 - Comfort pillow - Google Patents

Comfort pillow Download PDF

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Publication number
WO2003099079A2
WO2003099079A2 PCT/US2003/016486 US0316486W WO03099079A2 WO 2003099079 A2 WO2003099079 A2 WO 2003099079A2 US 0316486 W US0316486 W US 0316486W WO 03099079 A2 WO03099079 A2 WO 03099079A2
Authority
WO
WIPO (PCT)
Prior art keywords
viscoelastic
pillow
layer
layers
filler material
Prior art date
Application number
PCT/US2003/016486
Other languages
French (fr)
Other versions
WO2003099079A3 (en
Inventor
Gerda Wassilefky
Original Assignee
Tempur World, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=29584517&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=WO2003099079(A2) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Priority to AT03755483T priority Critical patent/ATE472955T1/en
Priority to DK03755483.9T priority patent/DK1507469T3/en
Priority to US10/489,233 priority patent/US7051389B2/en
Priority to AU2003248572A priority patent/AU2003248572B2/en
Priority to CA002487022A priority patent/CA2487022C/en
Priority to NZ536795A priority patent/NZ536795A/en
Priority to JP2004506611A priority patent/JP4785382B2/en
Application filed by Tempur World, Inc. filed Critical Tempur World, Inc.
Priority to MXPA04011652A priority patent/MXPA04011652A/en
Priority to EP03755483A priority patent/EP1507469B1/en
Priority to DE60333284T priority patent/DE60333284D1/en
Publication of WO2003099079A2 publication Critical patent/WO2003099079A2/en
Publication of WO2003099079A3 publication Critical patent/WO2003099079A3/en
Priority to US11/407,432 priority patent/US7530127B2/en
Priority to US11/443,460 priority patent/US7415742B2/en
Priority to US12/198,537 priority patent/US7735169B2/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B68—SADDLERY; UPHOLSTERY
    • B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G1/00—Loose filling materials for upholstery
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G9/00—Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G9/00—Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
    • A47G9/10—Pillows
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S5/00—Beds
    • Y10S5/948—Body support with unique, specific filler material
    • Y10S5/953—Comprising structurally defined foam material or configuration

Definitions

  • This invention relates generally to pillows or cushions, and more particularly to a pillow or cushion for therapeutic use.
  • the neck of a person lying in a supine or sidelying position is often out of alignment with the person's spine. This is commonly the case when the person's neck is supported by a pillow or multiple pillows such that the neck lies at an angle defined by the deflected height of the pillow(s), and this angle is typically not co-planar with the spine.
  • the deflected height of the pillow is closely related to its stiffness, which is conventionally provided by filling material disposed within a fabric covering.
  • Conventional filling material can include feathers, cotton, or a synthetic filler.
  • the invention provides a pillow having multiple foam components.
  • One embodiment of the present invention includes a pillow having a viscoelastic sleeve defining a cavity and filler material positioned within the cavity.
  • Another embodiment of the present invention includes a pillow having outer layers and a filler material comprised of granulated viscoelastic foam disposed between the outer layers.
  • Yet another embodiment of the present invention includes a pillow having outer layers of reinforcing fabric, intermediate layers of viscoelastic foam, and a filler material comprised of granulated viscoelastic foam disposed between the intermediate layers.
  • the present invention also includes a method for manufacturing a pillow.
  • the method includes providing a viscoelastic sleeve that defines a cavity, inserting filler material within the cavity, and closing the sleeve to maintain the filer material within the cavity.
  • the viscoelastic foam responds to changes in temperature such that body heat molds the pillow to conform to the curves of a body for comfort and support. This allows the shape of the pillow to more closely follow the contours of the body and to promote an improved alignment of the neck and spine when a person is in a supine or sidelying position.
  • a cover preferably encases the pillow and contours to the shape of the pillow.
  • the cover is removable, washable, and has a resealable slot through which the pillow may be inserted or removed.
  • the slot extends across an edge portion of the pillow and is preferably opened and closed by a zipper.
  • FIG. 1 is a perspective view illustrating a pillow embodying the present invention.
  • FIG. 2 is an exploded view of the pillow shown in FIG. 1.
  • FIG. 3 is a partial cross-sectional view of the pillow shown in FIG. 1.
  • FIGS. 1-3 illustrate a pillow 10 of the present invention having a sleeve construction formed of multiple layers.
  • the pillow 10 comprises a filler material 14 disposed between layers of viscoelastic foam 18.
  • the viscoelastic foam layers 18 possess specific thermally responsive properties which cause the pillow 10 to conform to the shape of the portion of a person's body that contacts the pillow 10.
  • the viscoelastic foam layers 18 have a lower stiffness or hardness at an elevated temperature as compared to the stiffness at a cooler temperature.
  • conventional pillow filler materials typically have a constant stiffness with respect to a changing temperature.
  • the body heat of the person acts to soften the portion of the pillow 10 in contact with the body, while the portion of the pillow 10 not contacting the body remains more firm.
  • the pillow 10 embodying the present invention allows for greater comfort over a conventional pillow by accommodating each user's body form.
  • the filler material 14 is granulated, or shredded, viscoelastic foam having a density of about 85 kg/m 3 .
  • a suitable density for the viscoelastic foam filler material 14 for an average weight pillow 10, for example can be between about 30 and about 140 kg/m 3 .
  • a suitable density for the viscoelastic foam filler material 14 for a light-weight pillow 10, for example can be less than about 40 kg/m 3 .
  • a suitable density for the viscoelastic foam filler material 14 for a heavy-weight pillow 10, for example can be greater than about 130 kg/m 3 .
  • the granulated viscoelastic foam utilized as the filler material 14 can have any density in accordance with the desired characteristics of the pillow 10.
  • a suitable viscoelastic foam filler material 14 possesses an indentation load deflection, or "ILD,” of 65% between 100-500 N loading, and a maximum 10% rebound according to the test procedure governed by the ASTM-D-1564 standard.
  • the granulated filler material 14 can be made up of recycled, virgin, or scrap viscoelastic material.
  • the granulated filler material 14 may consist of pieces of a nominal length, or the granulated filler material 14 may consist of pieces of varying lengths.
  • granulated filler material 14 may have a nominal length of about 1.3 cm.
  • granulated filler material 14 may consist of varying lengths between about 0.6 cm and about 2 cm.
  • the granulated filler material 14 can be as short as 0.3 cm and as long as 4 cm., or the filler material 14 can be any length in accordance with the desired characteristics of the pillow 10.
  • the granulated filler material 14 is comprised of 16-20% having a length longer than 2 cm, 38- 42% having a length between 1 and 2 cm, and 38-42% of the pieces shorter than 1 cm.
  • Significant cost savings and waste reduction can be realized by using scrap or recycled filler material 14 rather than virgin filler material 14.
  • the viscoelastic foam used as the filler material 14 is made from a polyurethane foam material, however, the filler material 14 can be made from any other viscoelastic polymer material that exhibits similar thermally-responsive properties.
  • the composition of the filler material 14 can be varied to alter the characteristics of the pillow 10 and the cost of the pillow 10.
  • the filler material 14 is a combination of granulated viscoelastic foam and a fiber material.
  • the fiber material can be made from any kind of textile, such as an organic textile (cotton) or a synthetic textile, which is often less expensive than viscoelastic foam.
  • the fiber material has a density of about 1 g/cm .
  • a suitable density for the fiber material for an average weight pillow 10, for example is 0.1 - 2 g/cm 3 .
  • a suitable density for the fiber material for a light- weight pillow 10 can be less than about 0.3 g/cm 3 .
  • a suitable density for the fiber material for a heavy-weight pillow 10, for example can be greater than about 1.8 g/cm 3 .
  • the fiber material utilized in combination with the granulated viscoelastic foam as the filler material 14 can have any density in accordance with the desired characteristics of the pillow 10.
  • the filler material 14 is comprised of about 50% fiber material, while the remaining composition includes the granulated viscoelastic foam.
  • a suitable range of fiber material in the filler material 14 for an average-cost pillow 10, for example can be between about 20% and about 80%.
  • a suitable range of fiber material in the filler material 14 for a more expensive pillow 10, for example, can be more than about 30% of the filler material 14.
  • a suitable range of fiber material in the filler material 14 for a less expensive pillow 10, for example can be greater than about 70% of the filler material 14.
  • the filler material 14 is a combination of granulated viscoelastic foam and polystyrene balls, which are often less expensive than viscoelastic foam.
  • the filler material 14 of this embodiment can also include an organic or synthetic fiber material depending on the desired characteristics of the pillow 10.
  • the polystyrene balls may consist of balls of a nominal diameter, or the polystyrene balls may consist of balls of varying diameters.
  • the polystyrene balls may have a nominal diameter of about 5mm.
  • the polystyrene balls may consist of varying diameters between about 1 mm and about 10 mm.
  • the polystyrene balls can also be as small as 0.5 mm and as long as 20mm, or the polystyrene balls can be any length in accordance with the desired characteristics of the pillow 10.
  • the filler material 14 is comprised of about 50% polystyrene balls, while the remaining composition includes the granulated viscoelastic foam.
  • a suitable range of polystyrene balls in the filler material 14 for an average-cost pillow 10, for example can be between about 20% and about 80%.
  • a suitable range of polystyrene balls in the filler material 14 for a more expensive pillow 10, for example can be less than about 30% of the filler material 14.
  • a suitable range of polystyrene balls in the filler material 14 for a less expensive pillow 10, for example can be greater than about 70% of the filler material 14.
  • the filler material 14 can also include granulated highly-elastic ("HE") foam in addition to the granulated viscoelastic foam.
  • HE foam is often less expensive than viscoelastic foam, thus yielding a potentially less expensive pillow 10.
  • the filler material can be comprised of any single filler described above or any combination of the fillers.
  • the filler material 14 can also include any conventional materials, such as feathers, granulated cotton, cotton fibers, etc.
  • the filler material 14 includes HE foam having a density of about 35 kg/m 3 .
  • a suitable density for the HE foam for an average weight pillow 10 can be between about 20 and about 50 kg/m 3 .
  • a suitable density for the HE foam for a lightweight pillow 10 can be less than about 25 kg/m 3 .
  • a suitable density for the HE foam for a heavyweight pillow 10, for example can be greater than about 45 kg/m 3 .
  • the HE foam utilized in the filler material 14 can have any density in accordance with the desired characteristics of the pillow 10.
  • the granulated HE foam may consist of pieces of a nominal length, or the granulated HE foam may consist of pieces of varying lengths.
  • the granulated HE foam may have a nominal length of about 1.3 cm.
  • the granulated HE foam may consist of varying lengths between about 0.6 cm and about 2 cm.
  • the granulated HE foam can be as short as 0.3 cm and as long as 4 cm., or the granulated HE foam can be any length in accordance with the desired characteristics of the pillow 10.
  • the granulated HE foam is comprised of 16-20% having a length longer than 2 cm, 38-42% having a length between 1 and 2 cm, and 38-42% of the pieces shorter than 1 cm.
  • the filler material 14 is comprised of about 50% granulated HE foam, while the remaining composition includes the granulated viscoelastic foam.
  • a suitable range of HE foam in the filler material 14 for an average cost pillow 10 is 20% - 80%.
  • a suitable range of granulated HE foam in the filler material 14 for a more expensive pillow 10, for example can be less than about 30% of the filler material 14.
  • a suitable range of granulated HE foam in the filler material 14 for a less expensive pillow 10, for example can be greater than about 70% of the filler material 14.
  • the filler material 14 is disposed between layers of viscoelastic foam 18.
  • the layers of viscoelastic foam 18 have a density of about 85 kg/m 3 .
  • a suitable density for the layers of viscoelastic foam 18 for an average weight pillow 10, for example can be between about 30 and about 140 kg/m 3 .
  • a suitable density for the layers of viscoelastic foam 18 for a lightweight pillow 10, for example can be less than about 40 kg/m .
  • a suitable density for the layers of viscoelastic foam 18 for a heavyweight pillow 10, for example can be greater than about 130 kg/m 3 .
  • the layers of viscoelastic foam 18 can have any density in accordance with the desired characteristics of the pillow 10.
  • the layers of viscoelastic foam 18 are preferably about 10 mm thick and have thermally-responsive properties similar to the granulated viscoelastic foam of the filler material 14.
  • a suitable thickness for the layers of viscoelastic foam 18 for an average weight pillow 10 can be between about 5 mm and 15 mm.
  • a suitable thickness for the layers of viscoelastic foam 18 for a lightweight pillow 10, for example can be less than about 7 mm.
  • a suitable thickness for the layers of viscoelastic foam 18 for a heavyweight pillow 10, for example can be greater than about 13 mm.
  • the layers of viscoelastic foam 18 are made from a polyurethane foam material, however, the layers of viscoelastic foam 18 can be made from any other viscoelastic polymer material that exhibits similar thermally-responsive properties.
  • the overall stiffness or hardness of the pillow 10 is dependent on the stiffness of the individual viscoelastic foam layers 18 and the filler material 14. As such, the overall stiffness or hardness of the pillow 10 may be affected by varying the stiffness of the individual viscoelastic foam layers 18 and/or the filler material 14. As shown in FIGS. 1-3, reinforcing fabric layers 22 are positioned on the outside of the layers of viscoelastic foam 18. The reinforcing fabric 22 acts as an anchor for stitches 26 that secure together the layers of reinforcing fabric 22 and the layers of viscoelastic foam 18.
  • the viscoelastic foam layers 18, which are less durable than the layers of reinforcing fabric 22, would have to directly anchor the stitches 26 such that the filler material 14 is secured between the viscoelastic foam layers 18.
  • the viscoelastic foam layers 18 would likely tear near the stitches 26 as a result of normal use of the pillow. Further, if the viscoelastic foam layers 18 were to tear, then the filler material 14 would spill out. Therefore, the reinforcing fabric layers 22 provide a measure of durability to the pillow 10.
  • the reinforcing fabric 22 is preferably made from a durable material, such as a cotton polyester blend.
  • a cover 30 surrounds and encases the pillow 10, and conforms to the shape of the pillow 10.
  • the cover 30 is preferably made from a durable and washable fabric material, such as a cotton/polyester blend.
  • a slot 34 extends across the cover 30 along the cover's edge.
  • the pillow 10 may be inserted into the cover 30 through the slot 34.
  • the pillow 10 may also be removed from the cover 30 through the slot 34 to facilitate cleaning of the cover 30.
  • the slot 34 is resealable to close the cover 30 around the pillow 10 and to open the cover 30 for removing the pillow 10.
  • a closure device is used to open and close the slot 34.
  • the closure device is a zipper 38, although the closure device could also comprise snaps, buttons, hook and loop fasteners, overlapping flaps, laces, or other similar fasteners.
  • the layers of viscoelastic foam 18 are sewn together with the layers of reinforcing fabric 22 to form a sleeve or casing having an open end, wherein the layers of viscoelastic foam 18 comprise the inner layers of the casing and the layers of reinforcing fabric 22 comprise the outer layers of the casing.
  • the filler material 14 is then inserted through the open end of the casing until the desired amount of filler material 14 is reached within the casing.
  • the open end is then sewn closed, thereby encasing the filler material 14 within the casing and defining a pillow 10.
  • the pillow 10 is then inserted within the cover 30 and the cover 30 is closed by the zipper 38.

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  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Otolaryngology (AREA)
  • Pulmonology (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Bedding Items (AREA)
  • Orthopedics, Nursing, And Contraception (AREA)
  • Transition And Organic Metals Composition Catalysts For Addition Polymerization (AREA)
  • Golf Clubs (AREA)
  • Medicines Containing Plant Substances (AREA)

Abstract

A pillow (10) including a viscoelastic sleeve (18) defining a cavity and filler material (14) positioned within the cavity.

Description

COMFORT PILLOW
Related Applications
This application claims the benefit of U.S. Provisional Patent Application Serial Number 60/383,169 filed on May 24, 2002, the entire contents of which is incorporated herein by reference.
Field of the Invention
This invention relates generally to pillows or cushions, and more particularly to a pillow or cushion for therapeutic use.
Background of the Invention
The neck of a person lying in a supine or sidelying position is often out of alignment with the person's spine. This is commonly the case when the person's neck is supported by a pillow or multiple pillows such that the neck lies at an angle defined by the deflected height of the pillow(s), and this angle is typically not co-planar with the spine. The deflected height of the pillow is closely related to its stiffness, which is conventionally provided by filling material disposed within a fabric covering. Conventional filling material can include feathers, cotton, or a synthetic filler.
Summary of the Invention To provide a pillow structure more likely to properly align the user's neck and spine, the invention provides a pillow having multiple foam components.
One embodiment of the present invention includes a pillow having a viscoelastic sleeve defining a cavity and filler material positioned within the cavity.
Another embodiment of the present invention includes a pillow having outer layers and a filler material comprised of granulated viscoelastic foam disposed between the outer layers.
Yet another embodiment of the present invention includes a pillow having outer layers of reinforcing fabric, intermediate layers of viscoelastic foam, and a filler material comprised of granulated viscoelastic foam disposed between the intermediate layers.
The present invention also includes a method for manufacturing a pillow. The method includes providing a viscoelastic sleeve that defines a cavity, inserting filler material within the cavity, and closing the sleeve to maintain the filer material within the cavity.
The viscoelastic foam responds to changes in temperature such that body heat molds the pillow to conform to the curves of a body for comfort and support. This allows the shape of the pillow to more closely follow the contours of the body and to promote an improved alignment of the neck and spine when a person is in a supine or sidelying position.
A cover preferably encases the pillow and contours to the shape of the pillow. The cover is removable, washable, and has a resealable slot through which the pillow may be inserted or removed. The slot extends across an edge portion of the pillow and is preferably opened and closed by a zipper.
Brief Description of the Drawings
FIG. 1 is a perspective view illustrating a pillow embodying the present invention. FIG. 2 is an exploded view of the pillow shown in FIG. 1.
FIG. 3 is a partial cross-sectional view of the pillow shown in FIG. 1.
Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
Detailed Description of the Preferred Embodiment
FIGS. 1-3 illustrate a pillow 10 of the present invention having a sleeve construction formed of multiple layers. The pillow 10 comprises a filler material 14 disposed between layers of viscoelastic foam 18. The viscoelastic foam layers 18 possess specific thermally responsive properties which cause the pillow 10 to conform to the shape of the portion of a person's body that contacts the pillow 10. The viscoelastic foam layers 18 have a lower stiffness or hardness at an elevated temperature as compared to the stiffness at a cooler temperature. Conversely, conventional pillow filler materials typically have a constant stiffness with respect to a changing temperature. The body heat of the person acts to soften the portion of the pillow 10 in contact with the body, while the portion of the pillow 10 not contacting the body remains more firm. As a result, the pillow 10 embodying the present invention allows for greater comfort over a conventional pillow by accommodating each user's body form.
In one embodiment of the present invention, the filler material 14 is granulated, or shredded, viscoelastic foam having a density of about 85 kg/m3. However, a suitable density for the viscoelastic foam filler material 14 for an average weight pillow 10, for example, can be between about 30 and about 140 kg/m3. Further, a suitable density for the viscoelastic foam filler material 14 for a light-weight pillow 10, for example, can be less than about 40 kg/m3. Likewise, a suitable density for the viscoelastic foam filler material 14 for a heavy-weight pillow 10, for example, can be greater than about 130 kg/m3.
Alternatively, the granulated viscoelastic foam utilized as the filler material 14 can have any density in accordance with the desired characteristics of the pillow 10. hi addition, a suitable viscoelastic foam filler material 14 possesses an indentation load deflection, or "ILD," of 65% between 100-500 N loading, and a maximum 10% rebound according to the test procedure governed by the ASTM-D-1564 standard.
The granulated filler material 14 can be made up of recycled, virgin, or scrap viscoelastic material. The granulated filler material 14 may consist of pieces of a nominal length, or the granulated filler material 14 may consist of pieces of varying lengths. For example, granulated filler material 14 may have a nominal length of about 1.3 cm. Also, granulated filler material 14 may consist of varying lengths between about 0.6 cm and about 2 cm. The granulated filler material 14 can be as short as 0.3 cm and as long as 4 cm., or the filler material 14 can be any length in accordance with the desired characteristics of the pillow 10. In one preferred embodiment of the invention, the granulated filler material 14 is comprised of 16-20% having a length longer than 2 cm, 38- 42% having a length between 1 and 2 cm, and 38-42% of the pieces shorter than 1 cm. Significant cost savings and waste reduction can be realized by using scrap or recycled filler material 14 rather than virgin filler material 14. The viscoelastic foam used as the filler material 14 is made from a polyurethane foam material, however, the filler material 14 can be made from any other viscoelastic polymer material that exhibits similar thermally-responsive properties.
The composition of the filler material 14 can be varied to alter the characteristics of the pillow 10 and the cost of the pillow 10. In another embodiment of the present invention, the filler material 14 is a combination of granulated viscoelastic foam and a fiber material. The fiber material can be made from any kind of textile, such as an organic textile (cotton) or a synthetic textile, which is often less expensive than viscoelastic foam. In one embodiment of the present invention, the fiber material has a density of about 1 g/cm . However, a suitable density for the fiber material for an average weight pillow 10, for example, is 0.1 - 2 g/cm3. Further, a suitable density for the fiber material for a light- weight pillow 10, for example, can be less than about 0.3 g/cm3. Likewise, a suitable density for the fiber material for a heavy-weight pillow 10, for example, can be greater than about 1.8 g/cm3. Alternatively, the fiber material utilized in combination with the granulated viscoelastic foam as the filler material 14 can have any density in accordance with the desired characteristics of the pillow 10. In one preferred embodiment of the invention, the filler material 14 is comprised of about 50% fiber material, while the remaining composition includes the granulated viscoelastic foam. However, a suitable range of fiber material in the filler material 14 for an average-cost pillow 10, for example, can be between about 20% and about 80%. Further, a suitable range of fiber material in the filler material 14 for a more expensive pillow 10, for example, can be more than about 30% of the filler material 14. Likewise, a suitable range of fiber material in the filler material 14 for a less expensive pillow 10, for example, can be greater than about 70% of the filler material 14.
In yet another embodiment of the present invention, the filler material 14 is a combination of granulated viscoelastic foam and polystyrene balls, which are often less expensive than viscoelastic foam. The filler material 14 of this embodiment can also include an organic or synthetic fiber material depending on the desired characteristics of the pillow 10. The polystyrene balls may consist of balls of a nominal diameter, or the polystyrene balls may consist of balls of varying diameters. For example, the polystyrene balls may have a nominal diameter of about 5mm. Also, the polystyrene balls may consist of varying diameters between about 1 mm and about 10 mm. The polystyrene balls can also be as small as 0.5 mm and as long as 20mm, or the polystyrene balls can be any length in accordance with the desired characteristics of the pillow 10.
In one preferred embodiment of the invention, the filler material 14 is comprised of about 50% polystyrene balls, while the remaining composition includes the granulated viscoelastic foam. However, a suitable range of polystyrene balls in the filler material 14 for an average-cost pillow 10, for example, can be between about 20% and about 80%. Further, a suitable range of polystyrene balls in the filler material 14 for a more expensive pillow 10, for example, can be less than about 30% of the filler material 14. Likewise, a suitable range of polystyrene balls in the filler material 14 for a less expensive pillow 10, for example, can be greater than about 70% of the filler material 14.
In another embodiment of the present invention, the filler material 14 can also include granulated highly-elastic ("HE") foam in addition to the granulated viscoelastic foam. HE foam is often less expensive than viscoelastic foam, thus yielding a potentially less expensive pillow 10. The filler material can be comprised of any single filler described above or any combination of the fillers. Alternatively, the filler material 14 can also include any conventional materials, such as feathers, granulated cotton, cotton fibers, etc. In one embodiment of the present invention, the filler material 14 includes HE foam having a density of about 35 kg/m3. However, a suitable density for the HE foam for an average weight pillow 10, for example, can be between about 20 and about 50 kg/m3. Further, a suitable density for the HE foam for a lightweight pillow 10, for example, can be less than about 25 kg/m3. Likewise, a suitable density for the HE foam for a heavyweight pillow 10, for example, can be greater than about 45 kg/m3. Alternatively, the HE foam utilized in the filler material 14 can have any density in accordance with the desired characteristics of the pillow 10.
The granulated HE foam may consist of pieces of a nominal length, or the granulated HE foam may consist of pieces of varying lengths. For example, the granulated HE foam may have a nominal length of about 1.3 cm. Also, the granulated HE foam may consist of varying lengths between about 0.6 cm and about 2 cm. The granulated HE foam can be as short as 0.3 cm and as long as 4 cm., or the granulated HE foam can be any length in accordance with the desired characteristics of the pillow 10. In one preferred embodiment of the invention, the granulated HE foam is comprised of 16-20% having a length longer than 2 cm, 38-42% having a length between 1 and 2 cm, and 38-42% of the pieces shorter than 1 cm.
In one preferred embodiment of the invention, the filler material 14 is comprised of about 50% granulated HE foam, while the remaining composition includes the granulated viscoelastic foam. However, a suitable range of HE foam in the filler material 14 for an average cost pillow 10, for example, is 20% - 80%. Further, a suitable range of granulated HE foam in the filler material 14 for a more expensive pillow 10, for example, can be less than about 30% of the filler material 14. Likewise, a suitable range of granulated HE foam in the filler material 14 for a less expensive pillow 10, for example, can be greater than about 70% of the filler material 14. As previously mentioned, the filler material 14 is disposed between layers of viscoelastic foam 18. In one embodiment of the present invention, the layers of viscoelastic foam 18 have a density of about 85 kg/m3. However, a suitable density for the layers of viscoelastic foam 18 for an average weight pillow 10, for example, can be between about 30 and about 140 kg/m3. Further, a suitable density for the layers of viscoelastic foam 18 for a lightweight pillow 10, for example, can be less than about 40 kg/m . Likewise, a suitable density for the layers of viscoelastic foam 18 for a heavyweight pillow 10, for example, can be greater than about 130 kg/m3. Alternatively, the layers of viscoelastic foam 18 can have any density in accordance with the desired characteristics of the pillow 10.
The layers of viscoelastic foam 18 are preferably about 10 mm thick and have thermally-responsive properties similar to the granulated viscoelastic foam of the filler material 14. Likewise, a suitable thickness for the layers of viscoelastic foam 18 for an average weight pillow 10, for example, can be between about 5 mm and 15 mm. However, a suitable thickness for the layers of viscoelastic foam 18 for a lightweight pillow 10, for example, can be less than about 7 mm. Further, a suitable thickness for the layers of viscoelastic foam 18 for a heavyweight pillow 10, for example, can be greater than about 13 mm. The layers of viscoelastic foam 18 are made from a polyurethane foam material, however, the layers of viscoelastic foam 18 can be made from any other viscoelastic polymer material that exhibits similar thermally-responsive properties.
The overall stiffness or hardness of the pillow 10 is dependent on the stiffness of the individual viscoelastic foam layers 18 and the filler material 14. As such, the overall stiffness or hardness of the pillow 10 may be affected by varying the stiffness of the individual viscoelastic foam layers 18 and/or the filler material 14. As shown in FIGS. 1-3, reinforcing fabric layers 22 are positioned on the outside of the layers of viscoelastic foam 18. The reinforcing fabric 22 acts as an anchor for stitches 26 that secure together the layers of reinforcing fabric 22 and the layers of viscoelastic foam 18. Without the reinforcing fabric layers 22, the viscoelastic foam layers 18, which are less durable than the layers of reinforcing fabric 22, would have to directly anchor the stitches 26 such that the filler material 14 is secured between the viscoelastic foam layers 18. In a pillow having this construction (not shown), the viscoelastic foam layers 18 would likely tear near the stitches 26 as a result of normal use of the pillow. Further, if the viscoelastic foam layers 18 were to tear, then the filler material 14 would spill out. Therefore, the reinforcing fabric layers 22 provide a measure of durability to the pillow 10. The reinforcing fabric 22 is preferably made from a durable material, such as a cotton polyester blend.
A cover 30 surrounds and encases the pillow 10, and conforms to the shape of the pillow 10. The cover 30 is preferably made from a durable and washable fabric material, such as a cotton/polyester blend. As shown in FIG. 1, a slot 34 extends across the cover 30 along the cover's edge. The pillow 10 may be inserted into the cover 30 through the slot 34. The pillow 10 may also be removed from the cover 30 through the slot 34 to facilitate cleaning of the cover 30. The slot 34 is resealable to close the cover 30 around the pillow 10 and to open the cover 30 for removing the pillow 10. A closure device is used to open and close the slot 34. hi the preferred embodiment, the closure device is a zipper 38, although the closure device could also comprise snaps, buttons, hook and loop fasteners, overlapping flaps, laces, or other similar fasteners.
During manufacture, the layers of viscoelastic foam 18 are sewn together with the layers of reinforcing fabric 22 to form a sleeve or casing having an open end, wherein the layers of viscoelastic foam 18 comprise the inner layers of the casing and the layers of reinforcing fabric 22 comprise the outer layers of the casing. The filler material 14 is then inserted through the open end of the casing until the desired amount of filler material 14 is reached within the casing. The open end is then sewn closed, thereby encasing the filler material 14 within the casing and defining a pillow 10. The pillow 10 is then inserted within the cover 30 and the cover 30 is closed by the zipper 38.

Claims

ClaimsLclaim:
1. A pillow comprising: a viscoelastic sleeve defining a cavity; and filler material positioned within the cavity.
2. The pillow of Claim 1 , wherein the sleeve includes a first viscoelastic layer; and a second viscoelastic layer, the first and second viscoelastic layers being connected together to form the cavity therebetween, wherein the filler material is positioned between the first and second viscoelastic layers.
3. The pillow of Claim 2, wherein the first viscoelastic layer and the second viscoelastic layer are between about 5 mm and 15 mm thick.
4. The pillow of Claim 3, wherein the first viscoelastic layer and the second viscoelastic layer are about 10 mm thick.
5. The pillow of Claim 2, wherein the first viscoelastic layer and the second viscoelastic layer have a density between about 30 kg/m and about 140 kg/m .
6. The pillow of Claim 5, wherein the first viscoelastic layer and the second viscoelastic layer have a density of about 85 kg/m3.
7. The pillow of Claim 2, further comprising a first fabric layer covering the first viscoelastic layer; and a second fabric layer covering the second viscoelastic layer.
8. The pillow of Claim 7, wherein the first and second fabric layers are connected to the first and second viscoelastic layers, respectively.
9. The pillow of Claim 8, wherein the first and second fabric layers are stitched to the first and second viscoelastic layers, respectively.
10. The pillow of Claim 1, further comprising a cover encasing the viscoelastic sleeve, the cover including a re-sealable slot.
11. The pillow of Claim 1 , wherein the filler material includes granulated viscoelastic foam.
12. The pillow of Claim 11, wherein the granulated viscoelastic foam has a density between about 30 kg/m3 and about 140 kg/m3.
13. The pillow of Claim 12, wherein the granulated viscoelastic foam has a density of about 85 kg/m3.
14. The pillow of Claim 11, wherein the granulated viscoelastic foam has a nominal length between about 0.6 cm and about 2 cm.
15. The pillow of Claim 14, wherein the granulated viscoelastic foam has a nominal length of about 1.3 cm.
16. The pillow of Claim 11 , wherein approximately 16% to 20% of the granulated viscoelastic foam include lengths longer than about 2 cm.
17. The pillow of Claim 11, wherein between approximately 38% to 42% of the granulated viscoelastic foam include lengths between about 1 cm and about 2 cm.
18. The pillow of Claim 11 , wherein approximately 38% to 42% of the granulated viscoelastic foam include lengths shorter than about 1 cm.
19. The pillow of Claim 1, wherein the filler material includes granulated viscoelastic foam and polystyrene balls.
20. The pillow of Claim 1 , wherein the filler material includes granulated viscoelastic foam and granulated highly-elastic foam.
21. A method for manufacturing a pillow, the method comprising: providing a viscoelastic sleeve that defines a cavity; inserting filler material within the cavity; and closing the sleeve to maintain the filer material within the cavity.
22. The method of Claim 21 , further comprising overlying a first viscoelastic layer with a second viscoelastic layer; connecting a portion of the first and second viscoelastic layers to form the sleeve containing the filler material; and connecting a remaining portion of the first and second viscoelastic layers to close the sleeve and maintain the filler material within the cavity.
23. The method of Claim 22, further comprising covering the first viscoelastic layer with a first fabric layer; and covering the second viscoelastic layer with a second fabric layer.
24. The method of Claim 23, further comprising connecting the first fabric layer to the first viscoelastic layer; and connecting the second fabric layer to the second viscoelastic layer.
25. The method of Claim 24, wherein connecting the first fabric layer with the first viscoelastic layer includes stitching together the first fabric layer with the first viscoelastic layer, and wherein connecting the second fabric layer with the second viscoelastic layer includes stitching together the second fabric layer with the second viscoelastic layer.
26. The method of Claim 21 , further comprising inserting the viscoelastic sleeve into a cover through a re-sealable slot; and sealing the slot to secure the viscoelastic sleeve within the cover.
27. The method of Claim 21, further comprising shredding viscoelastic material into individual lengths to form the filler material.
28. A method for manufacturing a pillow, the method comprising: providing at least two opposing viscoelastic foam layers and at least two reinforcing fabric layers covering the opposing viscoelastic foam layers; sewing together the viscoelastic foam layers and the reinforcing fabric layers to form a casing having an open end, the viscoelastic foam layers comprising respective inner layers of the casing, and the reinforcing fabric layers comprising respective outer layers of the casing; inserting filler material through the open end of the casing; and sewing together the open end of the casing to close the casing and secure therein the filler material.
PCT/US2003/016486 2002-05-24 2003-05-23 Comfort pillow WO2003099079A2 (en)

Priority Applications (13)

Application Number Priority Date Filing Date Title
DE60333284T DE60333284D1 (en) 2002-05-24 2003-05-23 HEALTH PILLOW
JP2004506611A JP4785382B2 (en) 2002-05-24 2003-05-23 Comfortable pillow
US10/489,233 US7051389B2 (en) 2002-05-24 2003-05-23 Comfort pillow
AU2003248572A AU2003248572B2 (en) 2002-05-24 2003-05-23 Comfort pillow
MXPA04011652A MXPA04011652A (en) 2002-05-24 2003-05-23 Comfort pillow.
NZ536795A NZ536795A (en) 2002-05-24 2003-05-23 Comfort pillow
DK03755483.9T DK1507469T3 (en) 2002-05-24 2003-05-23 comfort cushion
AT03755483T ATE472955T1 (en) 2002-05-24 2003-05-23 HEALTH PILLOW
CA002487022A CA2487022C (en) 2002-05-24 2003-05-23 Comfort pillow
EP03755483A EP1507469B1 (en) 2002-05-24 2003-05-23 Comfort pillow
US11/407,432 US7530127B2 (en) 2002-05-24 2006-04-20 Pillow and method of manufacturing a pillow
US11/443,460 US7415742B2 (en) 2002-05-24 2006-05-30 Comfort pillow
US12/198,537 US7735169B2 (en) 2002-05-24 2008-08-26 Comfort pillow

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US38316902P 2002-05-24 2002-05-24
US60/383,169 2002-05-24

Related Child Applications (3)

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US10489233 A-371-Of-International 2003-05-23
US11/407,432 Continuation-In-Part US7530127B2 (en) 2002-05-24 2006-04-20 Pillow and method of manufacturing a pillow
US11/443,460 Continuation US7415742B2 (en) 2002-05-24 2006-05-30 Comfort pillow

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WO2003099079A2 true WO2003099079A2 (en) 2003-12-04
WO2003099079A3 WO2003099079A3 (en) 2004-05-13

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US (3) US7051389B2 (en)
EP (2) EP1507469B1 (en)
JP (1) JP4785382B2 (en)
KR (1) KR100791159B1 (en)
CN (2) CN1668231A (en)
AT (1) ATE472955T1 (en)
AU (1) AU2003248572B2 (en)
CA (1) CA2487022C (en)
DE (1) DE60333284D1 (en)
DK (1) DK1507469T3 (en)
ES (1) ES2344736T3 (en)
MX (1) MXPA04011652A (en)
NZ (3) NZ556069A (en)
RU (2) RU2306837C2 (en)
SG (1) SG166671A1 (en)
WO (1) WO2003099079A2 (en)
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ZA (1) ZA200410267B (en)

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